East Kentucky Power Cooperative’s (EKPC’s) Cooper Station Unit 1 went online in 1965, and Unit 2 began operating in 1969. New air quality control equipment is being installed on Unit 2 to meet the requirements of EKPC’s consent decree with the U.S. Environmental Protection Agency. The new equipment includes: an FGD system to reduce sulfur dioxide (SO2) emissions, an SCR to reduce nitrous oxide (NOx) emissions and a PJFF to reduce particulate matter emissions.

Burns & McDonnell performed design studies to investigate alternative proven technologies that could meet the criteria of the consent decree. The selected FGD technology was a CFB dry system and fabric filter. This system provides the removal required for the pollutants listed in the consent decree, combined with an upstream SCR system for NOx control. Because the CFB dry scrubber includes a fabric filter downstream of the reactor, high removal percentages of PM emissions are expected. The existing electrostatic precipitator on Unit 2 will be taken out of service when the new systems are installed and operating. In addition, the CFB scrubber provides the additional benefit of being able to remove H2SO4 and mercury.

A project scoping report and cost estimate was prepared for the owner to support project planning and application for a certificate of public convenience and necessity.

Unlike wet FGD systems or spray dryer dry scrubber systems, no reagent slurry system is required for the CFB dry scrubber operation, because lime is hydrated and then fed directly into the reactor vessel. The system will have no wastewater discharge and may be able to consume some existing plant wastewater. The Cooper Station is near a city, and the use of the dry system normally results in no visible plume from the chimney. Because the treated flue gas will not be saturated, the existing chimney can be reused. If a new chimney had been required, it likely would have been required to be constructed to a height much taller than the existing stack.

Boiler modifications will be made to achieve the required operating conditions for the SCR, and a new tri-sector air heater will be installed downstream of the SCR.

The project is being performed under a multiple contract approach with Burns & McDonnell providing detailed design for the balance-of-plant systems and integration of subsystems. Several contracts were used to procure equipment including the FGD system and the SCR. Five construction contracts were prepared to complete the on-site work. Burns & McDonnell also provided permitting support.

Burns & McDonnell is performing the construction management for the project, working with several construction contractors installing equipment and materials. Burns & McDonnell is also providing field engineering staff on-site during construction and will provide personnel to assist with startup of the new systems.

Once the new facilities are in operation, plant emissions will be reduced significantly. The new AQCS equipment is expected to reduce SO2 emission by approximately 95 percent, reduce NOx emissions by 80 percent and particulate matter emissions by approximately 75 percent.

Construction began in spring 2010, and the equipment will be in operation in two years.